Flooring product and method for the production of the same

ABSTRACT

The present invention relates to a flooring product the surface of which consists of a naturally grown crystal structure which is held together by a binding agent. Moreover, the present invention discloses a method for the production of a flooring product.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority to German Patent 10 2007 014 496.4, filed Mar. 22, 2007 which is hereby expressly incorporated by reference in its entirety as part of the present disclosure.

BACKGROUND OF THE INVENTION

The invention relates to a flooring product and a method for the production of the same.

BRIEF DESCRIPTION OF RELATED ART

Generic flooring products are well known. They include, for example, floor tiles, wall tiles, panels etc., which may be coated with a layer of an attractive appearance, but which may also themselves consist of a material with an attractive appearance (e.g. stoneware, natural stone tiles). Flooring products can be applied directly onto the surface to be covered, but they can also be attached to carrier plates or the like. This is necessary, for example, if the underside of the flooring product is unsuited for attachment to an underlying surface.

The possibilities for producing such flooring products in various embodiments and different colored designs, from plain, simple colorations via various patterns to paintings are known in practice. For example, DE 697 01 983 T2 discloses a method in which it is possible to decorate ornamental stone materials with durable colored paintings.

Moreover, production methods for plates, tiles and panels of agglomerate materials are known which consist of various materials, such as sand, quartz, glass, ceramics, wood etc., and which are bonded with binding agents consisting of resins. In the process, the different materials are crushed, mixed and combined with the adhesive agents. The agglomerate is then compacted, hardened, ground, polished and cut to size. The fact that the naturally grown structures of the starting materials are being destroyed during crushing proves to be a drawback in this process. It is thus impossible to design different surfaces in such a way that they exhibit a crystalline structure as it occurs naturally in nature.

A mineral is a naturally occurring solid with a uniform chemical composition and a structure which is homogeneous even on a microscopic level. Most minerals are crystalline. In nature, naturally grown crystal structures frequently occur in cavities of rocks. These may be filled with crystals of various types and are called druses or geodes. In the case of a druse, the wall of the cavity is covered with crystals, whereas in a geode, the entire interior is filled by crystals.

BRIEF SUMMARY OF THE INVENTION

In the present application, naturally grown crystal structures are called rough pieces or specimens. The specimens are subdivided into two areas, a part which is colored throughout and a part which is not colored throughout. The part colored throughout in turn is characterized by its naturally grown crown comprising freely crystallized minerals. Externally, they exhibit a fixed geometric shape with well-defined natural surfaces that are oriented in fixed angles relative to one another. This part of the specimen is also called color layer, whereas the part which is not colored is called root.

Though the above described rough pieces are generally very decorative, further use as a decorative material, such as in tiles, slabs or panels is almost impossible. In relation, the individual pieces are too large, or too thick and have too great a weight. Accordingly, there is an interest in separating the non-colored part, that is, the root, which is superfluous as regards appearance, from the part that is of interest for decoration purposes, the color layer, without destroying the naturally grown crystal structures in the process.

The problem is that the crystalline build-up collapses as soon as the color layer is separated from the root. Moreover, the crystals of amethyst specimens, for example, lose their coherence amongst one another during the subsequent firing at the latest, so that the crystalline build-up collapses also in this case, when the color layer is separated from the crystal roots.

Citrine, for example, is the yellow-colored variety of quartz. Depending on the provenance of the citrine and the cause of the coloration, the hue varies from pale greenish yellow over orange to brown-orange. However, natural citrines are so rare that almost exclusively artificial citrines or dyed quartzes are being sold commercially. One variant of citrine production is based on the fact that violet amethysts, when heated to 300 to approximately 700° C., lose their violet color and take on an orange-yellow to brown color like a citrine. However, since the crystals of the amethyst specimens lose their coherence amongst one another during firing, as was already described above, it is not possible to produce artificial citrines that exhibit a naturally grown coherent build-up.

At present, no method is known from the state of the art for producing flooring products which exhibit the surface structure of naturally grown crystal structures and which are suitable for decorative purposes, such as further processing with the above-mentioned slabs, panels and/or tiles.

It is the object of the present invention to provide a flooring product having a naturally grown crystal structure, but which is nevertheless suitable for further use, such as further processing with the above-mentioned slabs, panels and/or tiles.

Moreover, it is the object of the invention to find a method for the production of such a flooring product.

According to the invention, the object is achieved by a flooring product and a method for the production of such a flooring product, the surface of which consists of a naturally grown crystal structure which is held together by a binding agent, wherein the crystal structure consists of a color layer of a naturally grown mineral. Due to the binding agent, it is possible to reduce the weight and size of the respective crystal specimens without the naturally grown crystal structures falling apart.

According to the invention, the flooring product may consist of different crystal structures, such as, for example, the crystal structures of citrine, amethyst, quartz, pyrite, etc., depending on which type of crystal specimen or which rough pieces are being used.

Preferably, the binding agent can be introduced into the interstices of the naturally grown crystal structure, and it can be a transparent adhesive of synthetic resin, such as, for example, a colorless two-component adhesive based on epoxy resin.

In another embodiment, the flooring product can be bonded by means of a binding agent with a carrier plate which can consist of different materials, such as glass, plexiglass, ceramics, and which can have a plurality of different shapes and colors.

Preferably, the surface of the flooring product according to the invention is sealed by the binding agent, so that no soiling, such as germs or fungi, can form in the interstices.

The crystal size of the flooring product preferably is 0.2 mm to 25 cm.

In the present description, a total of three production methods preferred by the inventor are being presented, which can be applied as necessary. Possible other methods for the production of flooring products according to the invention are not to be excluded by the methods described herein.

The focus in all the methods described is that the above-mentioned object, namely to provide a flooring product, the surface of which comprises the naturally grown crystal structure of the color layer, is to be achieved by a large reduction of the weight per unit area of the raw material.

Prior to the individual crystal specimens being processed, they should be freed from possible contaminations. This can be carried out in several steps, which include, for example, a wet cleaning and subsequent drying process, so that the residual water can evaporate.

1^(st) Method

In this method, the binding agent is directly introduced into the interstices of the naturally grown crystal structures, the binding agent preferably being a transparent adhesive of synthetic resin, such as, for example, a colorless two-component adhesive based on epoxy resin. The finished binding agent is preferably injected into the interstices of the crystals using thin needles. Generally, the needles have an interior width of 0.5 to 0.8 mm, but can have a different interior width if necessary. The pressure required for injecting the glue into the crystal interstices is generated, for example, by a Perfusor®. In principle, there is also the possibility of manually generating the pressure or to use other suitable devices. In the process, the binding agent penetrates the crystal interstices more deeply than the needles themselves due to the capillary effect. In this manner, the crystal interstices are being firmly connected with one another far into the root.

Prior to further processing, the individual rough specimens already provided with the binding agents should harden. The possible duration of hardening depends on external conditions, such as temperature, air humidity and the binding agent used, but is generally 24 hours. The mixing ratio of possible binding agents in turn depends on the manufacturer's data and preferably should not deviate from them.

The bonded crystal roots can then be cut to size, with the naturally grown crystal structure not falling apart anymore. Cutting to size itself is preferably carried out on a gem saw. Subsequent to the separation of the color layer from the root, it is advantageous if the underside, that is, the side facing away from the naturally grown crystal structure, or the cut side, is ground smooth and polished, whereby a possible further processing of the flooring product is facilitated.

In a preferred embodiment, the flooring product according to the invention can not only be directly applied onto a surface to be covered, for example, a wall or ceiling of a room, but also be bonded to carrier plates by means of the same or a similar binding agent. The carrier plates can consists of various materials, such as glass, plexiglass and ceramics and have various shapes and colors.

It is particularly advantageous if the surface of the flooring product is permanently sealed in a further step. Soiling of the surface by, for example, lime and other elements occurring in the water can thus be counteracted. The formation of germs and fungi in the interstices between the crystals can also be reduced or even prevented. This is particularly advantageous if the flooring product is used in sanitary rooms.

2^(nd) Method

To a large extent, this method is carried out analogously to the first method. In this case, however, the binding agent is not introduced directly into the interstices of the naturally grown crystal structures, rather, holes are drilled into the specimen between the color layer and the root, if possible directly underneath the color layer, using a drill, preferably a diamond drill. The binding agent is introduced into these holes, and the holes should be drilled so close to one another that a complete gluing of the roots can be ensured. The subsequent processing is carried out in the same way as in the first method.

3^(rd) Method

In this method, a type of grinding putty is used as a binding agent. In a first step, the individual specimens must be heated in order for the necessary coherence between the grinding putty and the naturally grown crystal structure to be ensured. The type of heating should in this case be selected such that a soiling of the naturally grown crystal structure is avoided. Heating on an electric plate has in this case proven particularly advantageous.

When the specimens are heated, they can be coated with a liquefied grinding putty. The specimens already provided with the binding agents should subsequently harden prior to further processing also in this method. After the grinding putty has hardened, the crystals remain fixed and can be cut to size without falling apart when the color layer is separated from the root.

The cut flooring product is then applied either directly onto the surface to be finally coated, or onto a carrier plate. The flooring product or the grinding putty, respectively, is then heated again so that the grinding putty can be removed again from the naturally grown crystal structure. Cleaning the crystal structure, for example by means of an alcohol-containing solution, is advantageous.

In principle, all three methods can also be combined with one another. It is also very important that it is generally not possible to exactly separate the color layer from the root; rather, the transition of the specimen from the root into the color layer, and thus, the position of the separation, is continuous. In order to obtain the color layer in as safe a manner as possible, separation is mostly carried out in the area of the root, as close to the color layer as possible. Thus, the binding agent can also glue the area of the root adjacent to the color layer, which automatically leads to the color layer not falling apart either.

In all three methods, the flooring product according to the invention can be joined on a surface, such as, for example, a carrier plate, a table, a wall or a tabletop. It is possible in the process that individual crystals have to be broken off from the flooring product so that adjacent flooring products can be better joined. It may also become necessary that individual interstices of adjacent flooring products have to be filled with individual crystals so that a more uniform total structure is created. It may be advantageous for such additional work to use the binding agent which was also used for the production of the flooring product.

It is possible to adapt the flooring product to any shapes or colors.

One possible embodiment of a carrier plate mentioned above can consist of glass. Glass makes it possible to provide the finished product with a very high strength. In the process, the flooring product can be firmly bonded with the glass by means of a suitable binding agent. Tempered safety glass can be used if a predetermined breaking point is required. The latter can be produced using suitable cutting devices or machines. Moreover, laminated safety glass can also be used as a carrier plate if high pressures may occur during installation or later use, and if no predefined, predetermined breaking point is required. In the case of a possible processing using plexiglass, the latter is used in a preferred thickness of from 0.5 to 1.0 mm. Plexiglass has the great advantage that a significant reduction of the total load and a very low structural height can be achieved in the case of constructions having a limited or prescribed weight.

In a particularly advantageous embodiment, colored glass types or plexiglass in the hues of the stones to be used can be used. The natural coloring of the minerals to be used can thus be enhanced. The intensity of the transparency to light can be adjusted in a correspondingly variable manner. It is advantageous if the surface of the carrier materials is smooth on the side on which the flooring product is applied, and matte, rough or sandblasted on the other side.

Flooring products according to the invention can be used in a plurality of different areas of application. In the building and construction industry, the flooring product can be used, for example, as wall claddings, ceiling decorations and flat room decorations. Due to the low weight and low structural height, the flooring product is also suitable in areas in which a low weight is of decisive importance, such as, for example, in the construction of cruise ships, motor yachts and yachts. In the hotel and catering trade, the flooring product can be used, for example, for decorative purposes in wellness areas and restaurants.

The flooring product can also be used in the jewelry industry, for example in the production of belt buckles, pendants, tie pins, brooches or rings. In the production of pendants, for example, particular importance is attached to the rear. A possible production of pendants with the flooring product could look like this: the rear of a piece of flooring product is ground and cut. Moreover, a flooring product of the same size can be produced from the same specimen, in which all sides, both the rear and the front with the naturally grown crystal structure, are ground and polished. The two parts can then be glued together by means of the binding agent, and the edges can also be ground and polished. A pendant with a rear that matches in color, but is nevertheless smoothly polished, and with a front with a naturally grown crystal structure would thus be produced.

Also, use of the flooring product in connection. with massage mats in physical therapy would be conceivable.

In the areas of refurbishment, in old buildings, in modernizations, in shipbuilding or lightweight construction, or in decorations, the processing of the flooring product can be carried out either on plexiglass carriers or directly on the surface to be covered.

In principle, there are no fixed basic shapes of the flooring product. They always result from the respective areas of application and the customers' wishes.

In the following, the terms of the present invention used in the description will be described with reference to the attached drawing.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 shows a specimen, or rough piece,

FIG. 2 shows an already separated specimen with a non-colored root and a colored color layer and

FIG. 3 shows a finished flooring product.

DETAILED DESCRIPTION OF THE INVENTION

First, reference is made to FIG. 1, in which a specimen 60, or rough piece, is to be illustrated by way of example. This is subdivided into a non-colored part, the root 61, and a colored part, the color layer 61. The color layer 61 has a surface 40 in the shape of a naturally grown crystal structure 20. The naturally grown crystal structure 20 is held together in the root 62. If the color layer 61 were separated from the root 62, the naturally grown crystal structure 20 would lose its coherence and be destroyed. In order to prevent this from happening, a binding agent 30 is introduced into the interstices 21 of the naturally grown crystal structure 20 prior to the color layer 61. being separated from the root 62. It is thus accomplished that the crystal structure 20 is glued completely. In an alternative method, holes 80 are drilled into the specimen 60 between the color layer 61 and the root 62, if possible directly underneath the color layer 61, using a drill, preferably a diamond drill. The binding agent 30 is then introduced into the holes 80, so that a complete gluing of the crystal structure 20 ensured also in this method.

A non-destructive separation of the color layer 61 from the root 62 as shown in FIG. 2 is possible in all of these methods once the binding agent 30 has hardened. Due to the fact that the color layer 61 shown in FIG. 2 is already glued by a binding agent 30, it already forms the flooring product 10 according to the invention. FIG. 3 shows a flooring product 10 according to the invention. The interstices 21 filled with a binding agent are clearly visible.

The invention is not limited to the exemplary embodiments described. They merely serve the purpose of illustrating the invention. 

1. Flooring product (10) comprising a surface (40) of a naturally grown crystal structure (20) which is held together by a binding agent (30), wherein the crystal structure (20) consists of a color layer (61) of a naturally grown mineral.
 2. Flooring product (10) according to claim 1, wherein the crystal structure (20) is comprised of the color layer (61) of a naturally grown specimen (60) selected from the group consisting of citrine, amethyst, quartz, and pyrite.
 3. Flooring product (10) according to claim 1, wherein the binding agent (30) is introduced into the interstices (21) of the naturally grown crystal structure (20).
 4. Flooring product (10) according to claim 1, wherein the binding agent (30) is a transparent adhesive of synthetic resin.
 5. Flooring product (10) according to claim 1, wherein the flooring product (10) is connected to a carrier plate (50).
 6. Flooring product (10) according to claim 5, wherein the carrier plate (50) is comprised of a material selected from the group consisting of glass, plexiglass, and ceramics.
 7. Flooring product (10) according to claim 1, wherein the surface (40) of the flooring product (10) is sealed by a binding agent (30).
 8. A method for the production of a flooring product (10) comprising the steps of: bonding a naturally grown crystal structure (20) of a color layer (61) of a specimen (60) by means of a binding agent (30), wherein the binding agent (10) is introduced into the interstices (21) of the naturally grown crystal structure (20), and separating the color layer (61) from a root (62) of the specimen (60).
 9. The method for the production of a flooring product (10) according to claim 8, wherein the binding agent (30) is introduced into holes (80) that were drilled with a drill into the specimen (60) between the root (62) and the color layer (61).
 10. The method for the production of a flooring product (10) according to claim 8, wherein grinding putty (70) is used as the binding agent (30) and is poured over the naturally grown crystal structure (20) of the color layer (61).
 11. The method for the production of a flooring product (10) according to claim 10, wherein the grinding putty (70) is removed again from the color layer (61) after the separation of the color layer (61) from the root (62) and the subsequent attachment of the color layer (61) on a surface.
 12. The method for the production of a flooring product (10) according to claim 1 further comprising the step of connecting the flooring product (10) to a carrier plate (50). 